Download Guardian Technologies 004988-4 Portable Generator User Manual

Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number: 004988-4
27kW NG, 30kW LP Vapor
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
INTRODUCTION
Thank you for purchasing this model of the standby
generator set.
Every effort was expended to make sure that the
information and instructions in this manual are both
accurate and current at the time the manual was written. However, the manufacturer reserves the right to
change, alter or otherwise improve this product(s) at
any time without prior notice.
‹ READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service
or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully. Their
definitions are as follows:
DANGER
The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer also strongly recommends instructing other users to properly
start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.
‹ OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by an Authorized
Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the
owner/operator and, as such, are not considered
defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
Proper maintenance and care of the generator ensures
a minimum number of problems and keep operating
expenses at a minimum. See the Authorized Service
Dealer for service aids and accessories.
After this heading, read instructions that, if not
strictly complied with, will result in personal injury
or property damage.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by an Authorized Service Dealer or other
competent, qualified contractor. Installation of this
equipment is not a “do-it-yourself” project.
After this heading, read instructions that, if not
strictly complied with, may result in personal injury
or property damage.
‹ HOW TO OBTAIN SERVICE
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
When the generator requires servicing or repairs,
contact an Authorized Service Dealer for assistance.
Service technicians are factory-trained and are capable of handling all service needs.
When contacting an Authorized Service Dealer about
parts and service, always supply the complete model
number of the unit as given on the front cover of this
manual or on the DATA LABEL affixed to the unit.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compliance with the special instructions while performing the
service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
symbol points out important safety informa This
tion that, if not followed, could endanger personal
safety and/or property of others.
 This symbol points out potential explosion hazard.
 This symbol points out potential fire hazard.

This symbol points out potential electrical shock
hazard.
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
OR
Locate us on the web at:
www.generac.com
2
Table of Contents
Liquid-cooled 30 kW Generators
INTRODUCTION ............................................... IFC
Section 3 — OPERATION ................................ 12
3.1
SAFETY RULES ....................................................2
Using a Standard “GTS” Transfer Switch ...........12
3.2
Control Console Components..............................13
Section 1 — GENERAL INFORMATION ............. 4
3.3
Manual Transfer and Startup ..............................14
1.1
Generator ..............................................................4
3.4
Engine Governor Adjustments ............................14
1.2
Transfer Switch .....................................................4
3.5
Retransfer and Shutdown ...................................14
1.3
Automatic System Operation .................................4
3.6
Automatic Operation ...........................................14
1.4
Generator AC Connection Systems........................4
3.7
Weekly Exercise Cycle .........................................15
1.5
Main Circuit Breaker.............................................4
Section 4 — MAINTENANCE ........................... 15
1.6
Generator Fuel System ..........................................5
4.1
1.7
Engine Protective Devices ......................................5
Maintenance Performed by Authorized
Service Facilities ..................................................15
1.8
Unpacking .............................................................6
4.2
Cooling System....................................................15
1.9
Lifting the Generator .............................................6
4.3
Overload Protection for Engine DC
Electrical System.................................................16
4.4
Checking Fluid Levels .........................................16
4.5
Maintenance Owner/Operator
Can Perform ........................................................16
1.13 Torque Specifications ............................................8
4.6
Miscellaneous Maintenance .................................18
1.14 Engine Oil Recommendations ...............................8
4.7
Scheduled Maintenance.......................................20
1.10 Specifications ........................................................7
1.11 Fuel Consumption .................................................7
1.12 Reconfiguring the Fuel System ..............................7
1.15 Coolant Recommendations ....................................8
1.16 Before Installation .................................................8
Section 2 — INSTALLATION ............................. 8
2.1
Standby Generator Installation .............................8
2.2
Generator Location ...............................................9
2.3
Generator Mounting and Support .........................9
2.4
Basic Standby Electric System ..............................9
2.5
Emergency Circuit Isolation Method ...................10
2.6
Total Circuit Isolation Method .............................10
2.7
Grounding the Generator ....................................10
2.8
Generator AC Neutral Connections .....................10
2.9
Transfer Switch Start Signal Connections ...........10
Section 5 — TROUBLESHOOTING ................. 23
Section 6 — NOTES........................................ 24
Section 7 — INTALLATION DIAGRAM ............ 25
Section 8 — ELECTRICAL DATA .................... 26
Section 9 — EXPLODED VIEWS AND
PARTS LISTS ............................. 30
Section 10 — WARRANTY .................Back Cover
2.10 Battery Installation ..............................................11
2.11 Preparation Before Start-Up ................................11
1
IMPORTANT SAFETY INSTRUCTIONS
Liquid-cooled 30 kW Generators

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators, potential operators, and service and repair technicians for this equipment.
 followed during installation and maintenance of the generator and batteries.
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be


WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.

WARNING:

This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if
it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and fundamental rules or precautions.
The manufacturer-cannot-anticipate-every-possible-circumstance that might-involve-a-hazard.-The-warnings-in
this manual, and on tags and decals affixed to the unit
are, therefore,-not-all-inclusive. If using a procedure,
work method or operating technique that the manufacturer does not specifically recommend, ensure that it
is safe for others. Also make sure the procedure, work
method or operating technique utilized does not render
the generator unsafe.
DANGER
the safe design of this generator,
 Despite
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or maintain
this equipment.
lethal voltages are generated by these
 Potentially
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
of the generator are rotating and/or hot dur Parts
ing operation. Exercise care near running generators.
2


 GENERAL HAZARDS 
• For safety reasons, The manufacturer recommends
that this equipment be installed, serviced and repaired
by an Authorized Service Dealer or other competent,
qualified electrician or installation technician who is
familiar with applicable codes, standards and regulations. The operator also must comply with all such
codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is installed, operated and serviced in accordance
with the manufacturer’s instructions and recommendations. Following installation, do nothing that might
render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
• The engine exhaust fumes contain carbon monoxide
gas, which can be DEADLY. This dangerous gas,
if breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason,
adequate ventilation must be provided. Exhaust
gases must be piped safely away from any building
or enclosure that houses the generator to an area
where people, animals, etc., will not be harmed. This
exhaust system must be installed properly, in strict
compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts,
fans, and other moving or hot parts. Never remove
any drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases
and to ensure correct generator operation. Do not
alter the installation or permit even partial blockage
of ventilation provisions, as this can seriously affect
safe operation of the generator.
• Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all
times. Never work on the equipment when physically
or mentally fatigued.
IMPORTANT SAFETY INSTRUCTIONS
Liquid-cooled 30 kW Generators
• Inspect the generator regularly, and promptly repair
or replace all worn, damaged or defective parts using
only factory-approved parts.
• Before performing any maintenance on the generator,
disconnect its battery cables to prevent accidental
start-up. Disconnect the cable from the battery post
indicated by a NEGATIVE, NEG or (–) first. Reconnect
that cable last.
• Never use the generator or any of its parts as a step.
Stepping on the unit can stress and break parts, and
may result in dangerous operating conditions from
leaking exhaust gases, fuel leakage, oil leakage, etc.
 ELECTRICAL HAZARDS 
• All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and
dangerous voltages to the transfer switch as well as
the standby generator. Avoid contact with bare wires,
terminals, connections, etc., on the generator as well
as the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before
operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface
to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry
wooden platform. Work on the equipment only while
standing on such insulative mats.
• The National Electrical Code (NEC), Article 250
requires the frame and external electrically conductive parts of the generator to be connected to an
approved earth ground and/or grounding rods. This
grounding will help prevent dangerous electrical
shock that might be caused by a ground fault condition in the generator set or by static electricity. Never
disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are
positively turned off at their source. Failure to do so
will result in hazardous and possibly fatal electrical
shock.
• Connecting this unit to an electrical system normally
supplied by an electric utility shall be by means of a
transfer switch so as to isolate the generator electric
system from the electric utility distribution system
when the generator is operating. Failure to isolate the
two electric system power sources from each other
by such means will result in damage to the generator
and may also result in injury or death to utility power
workers due to backfeed of electrical energy.
• Generators installed with an automatic transfer
switch will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below
an acceptable preset level. To prevent such automatic
start-up and possible injury to personnel, disable
the generator’s automatic start circuit (disconnect
battery cables, etc.) before working on or around the
unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement, such
as a dry rope or board, to free the victim from the live
conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
 FIRE HAZARDS 
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguisher
properly charged and be familiar with its use. If there
are any questions pertaining to fire extinguishers,
consult the local fire department.
 EXPLOSION HAZARDS 
• Properly ventilate any room or building housing the
generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel
or oil spills immediately. Ensure that no combustible
materials are left in the generator compartment, or
on or near the generator, as FIRE or EXPLOSION
may result. Keep the area surrounding the generator
clean and free from debris.
• These generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating
the storage and handling of fuels. Inspect the unit’s
fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed,
purged and leak tested according to applicable fuelgas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids
such as natural gas and liquid propane (LP) gas are
extremely EXPLOSIVE. Natural gas is lighter than air,
and LP gas is heavier than air; install leak detectors
accordingly.
3
Section 1 - General Information
Liquid-cooled 30 kW Generators
1.1
GENERATOR
1.3
This equipment is a liquid-cooled, engine-driven
generator set. The generator is designed to supply
electrical power that operates critical electrical loads
during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure
and is intended for outdoor installation only. Use
this generator as a source of electrical power for the
operation of 120 and/or 240VAC, single-phase loads.
this generator is used to power electrical load
 Ifcircuits
normally powered by a UTILITY power
source, it is required by code to install a transfer switch. The transfer switch must effectively
isolate the electric system from the utility distribution system when the generator is operating
(NEC 701). Failure to isolate an electrical system
by such means results in damage to the generator and may also result in injury or even death
to utility power workers due to backfeed of
electrical energy.
1.2
TRANSFER SWITCH
This generator system may include a matched automatic transfer switch which is intended to be used
in conjunction with the generator. It is supplied in
a NEMA 3R enclosure. The NEMA 3R enclosure is
weather proof and can be used indoors or outdoors.
Follow these rules:
• Install the transfer switch on a firm, sturdy supporting structure.
• To prevent switch distortion, level the switch if
necessary. This can be done by placing washers
between the switch enclosure and the mounting
surface.
• Never install the switch where water or any corrosive substance might drip onto the enclosure.
• Protect the switch at all times against excessive
moisture, dust, dirt, lint, construction grit and corrosive vapors.
If a transfer switch is not included, one may be purchased separately from an Authorized Dealer.
AUTOMATIC SYSTEM OPERATION
When this generator, along with a transfer switch, has
been installed and interconnected, a circuit board
in the generator panel constantly monitors UTILITY
power source voltage. Should that voltage drop below
a preset value, and remain at such a low state for
a preset amount of time, the generator cranks and
starts. After the generator starts, the transfer switch
transfers load circuits so the generator can power
them.
When UTILITY source voltage has been restored, the
switch re-transfers back to the UTILITY source voltage and the generator then shuts down.
Please reference the transfer switch manual for specific information.
1.4
GENERATOR AC CONNECTION
SYSTEMS
The generator was shipped from the factory with its
stator AC output leads connected in a single-phase,
three-wire generator AC connection system (Figure
1.1). The stator assembly in this system consists of
a pair of stationary windings, with two leads brought
out of each winding. Each single winding can supply 120VAC, 60 Hertz. When the two windings are
connected in series, a 240VAC, 60 Hertz AC output
results. Typically the two HOT leads in the circuit
are wires 11 and 44. The NEUTRAL leads are the
junction of Wires 22 and 33. The NEUTRAL is not
grounded.
Figure 1.1 - Generator AC Connection System
1.5
MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included with
the unit as shipped from the factory. The breaker for
each unit is described in Figure 1.2.
Figure 1.2 - Main Circuit Breaker
4
Model
Rating
004988-4
27,000 NG
30,000 LP
Phase
Actual Current
C/B Rating*
1
112.5
1
125.0
* Amp Rating of C/B structured under model.
150
150
Circuit Breaker
150A QN2
150A QN2
Section 1 - General Information
Liquid-cooled 30 kW Generators
1.6
GENERATOR FUEL SYSTEM
Figure 1.4 - Low Oil Pressure Switch
The unit has been factory tested and adjusted using a
natural gas fuel system. If propane (LP) gas is necessary, contact an authorized service dealer.
Fuel pressure for a natural gas set up should be five
inches to 14 inches of water column (0.18 to 0.5
psi) at all load ranges.
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
NOTE:
A seperate gas line and regulator may be needed
to assure proper gas pressure to the generator.
Improper gas pressure can cause hard starting and
affect engine durability.
fuels such as natural and LP (propane)
 Gaseous
gas are highly explosive. Even the slightest
spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural
gas, which is lighter than air, tends to collect in
high areas. LP gas is heavier than air and tends
to settle in low areas.
1.7
ENGINE PROTECTIVE DEVICES
The engine has several safety switches which cause
the engine to automatically shut down under the
following conditions: low oil pressure, high coolant
temperature, engine overspeed, low coolant level or
overcrank (Figure 1.3).
NOTE:
The Low Oil Pressure, High Coolant Temperature
and Low Coolant Level are not monitored for the
first 10 seconds of engine run time.
‹ 1.7.2
HIGH COOLANT TEMPERATURE
SWITCH
This normally open (N.O.) thermostatic switch has
sensing tip which is immersed in captive coolant.
Should coolant temperature exceed about 230°F
(110°C), the switch contacts close. This causes the
engine to shut down automatically and turns on
the high coolant temperature/low coolant level LED
(Figure 1.5).
Figure 1.5- High Coolant Temperature Switch
Figure 1.3 - Engine Protective Devices
LOW OIL
PRESURE
SWITCH
LOW COOLANT
LEVEL SWITCH
HIGH
COOLANT
TEMPERATURE
SWITCH
‹ 1.7.1
LOW OIL PRESSURE SWITCH
This switch is normally-closed (N.C.) but is held open
by engine oil pressure during engine running. Should
operating oil pressure drop below about 8-10 psi (5568 kPa), the switch contacts close, the engine shuts
down automatically, and the low oil pressure LED is
turned ON (Figure 1.4).
‹ 1.7.3
LOW COOLANT LEVEL SWITCH
Should engine coolant level drop below the level of
the high coolant temperature switch, it is possible for
the engine to overheat without automatic shutdown.
To prevent such overheating without automatic shut
down, the engine has a low coolant level sensor. If the
engine coolant drops too low, the engine automatically shuts down and turns on the high coolant temperature/low coolant level LED (Figure 1.6 on page 6).
5
Section 1 — General Information
Liquid-cooled 30 kW Generators
Figure 1.6 - Low Coolant Level Sensor
‹ 1.7.7
LOW BATTERY
The engine control board continually monitors the
battery voltage and turns on the low battery LED
if the battery voltage falls below 11.0 VDC for one
minute. Low battery voltage is a non-latching alarm,
which will automatically clear if the battery voltage
rises above 11.0 VDC.
The control system will not attempt to start the
engine if there is a low battery condition, however, if
the engine is already running when the low battery
condition occurs, the engine will continue to run as
long as possible.
Battery voltage is NOT monitored during the crank
cycle.
‹ 1.7.4
OVERSPEED SHUTDOWN
The engine control board receives AC frequency signals from an engine run winding in the alternator.
Should AC frequency exceed about 72 Hertz for three
seconds or 75 Hertz instantaniously, the engine shuts
down and the overspeed LED turns on. Should AC
frequency exceed about 72 Hertz, circuit board action
will automatically shutdown the engine (Figure 1.7).
Figure 1.7 - Printed Circuit Board Assembly
R44
LED1
C27
Q2
2
C9
J2
C26
U7
C4
‹ 1.7.8
ALARM RESET
If the engine control board shuts down the generator for any of the above reasons, the engine remains
stopped until the alarm is cleared by placing the
AUTO/OFF/MANUAL switch into the OFF position.
‹ 1.7.9
DC FUSES
These fuses are located on the front panel of the control system. They protect the panel wiring and components from damaging overload. Always remove the
15 amp main fuse before working on the generator.
The unit will not start or crank if this fuse is blown.
Replace the fuse with one of the same size, type, and
rating (main AGC-15, battery charger AG4).
D10
C21
1.8
UNPACKING
C30
‹ 1.8.1 UNPACKING PRECAUTIONS
C2
RL1
RL2
R25
R1
R48
D17
R49
U1
J1
L3
.VER 6094E0 #BCP
D19
Handle shipping cartons and crates with care. Use
care to avoid damage from dropping, bumping, collision, etc. Store and unpack cartons with the proper
side up, as noted on the shipping carton.
‹ 1.8.2 INSPECTION
‹ 1.7.5
RPM SENSOR LOSS
If the engine control board does not receive a proper
rpm signal from the starter during cranking or running, it shuts down the engine on rpm sensor loss
and flash the overspeed LED.
‹ 1.7.6
OVERCRANK SHUTDOWN
The engine control board uses a cyclic cranking process when attempting to start the engine. The first
crank cycle is a 15-second crank followed by a sevensecond rest. This is followed by five more crank
cycles each with a seven-second crank followed by a
seven-second rest.
If the engine fails to start after all six attempts, the
start attempt is stopped and the overcrank LED’s
illuminated.
6
After unpacking, carefully inspect the generator for
any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix their signature under
the consignor’s memo of loss or damage.
1.9
LIFTING THE GENERATOR
lifting or hoisting equipment is used, be
 When
careful not to touch overhead power lines. The
generators weight of more than 900 pounds
requires proper tools, equipment, and qualified
personnel to be used in all phases of handling
and unpacking.
Section 1 — General Information
Liquid-cooled 30 kW Generators
1.10 SPECIFICATIONS
Fuel pressure for a natural gas set up should be five
inches to 14 inches of water column (0.18 to 0.5
psi) at all load ranges.
‹ 1.10.1 GENERATOR SPECIFICATIONS
Single-phase
Model
Rated Max. Cont.
AC Power Output (kW)
Rated voltage (volts)
No. of Rotor Poles
Driven Speed of Rotor
Rotor Excitation System
Type of Stator
Rotor/Stator Insulation
004988-4
27 (NG), 30 (LP)
120/240
4
1800
Direct excited brush type
4 Wire
Class F/H
‹ 1.10.2 ENGINE SPECIFICATIONS
Make ........................................................................................................Ford
Displacement .................................................................................... 3.0 liters
Cylinder Arrangement ...............................................................................V-6
Valve Arrangement ................................................................Overhead Valve
Firing Order ..................................................................................1-4-2-5-3-6
Number of Main Bearings ............................................................................4
Compression Ratio .............................................................................9.3 to 1
No. of Teeth on Flywheel ..........................................................................164
Ignition Timing at 1800 rpm...............................................30 degrees BTDC
Spark Plug Gap ...................................................................0.042-0.046 inch
Recommended Spark Plugs
Motor Craft ..........................................................................AG, SF 32PGM
Oil Pressure.....................................................................................40-50 psi
Crankcase Oil Capacity .........................................5.0 U.S. quarts (4.7 liters)
Recommended Engine Oil .......................................................... SAE 5W-20
Type of Cooling System .................................. Pressurized, closed recovery
Cooling Fan ................................................................................Pusher Type
Cooling System Capacity .................................. 3.0 U.S. gallons (11.4 liters)
Recommended Coolant............................................. Use a 50-50 mixture of
ethylene glycol base and de-ionized water.
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
1.12 RECONFIGURING THE FUEL
SYSTEM
NOTE:
All models are configured for natural gas from the
factory.
To reconfigure the fuel system from NG to LP vapor,
follow these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
port (Port 1) of the demand regulator (Figure
1.8).
3. Remove the brass hose fitting from the outlet port
(Port 1) of the demand regulator.
4. Remove pipe plug from Port 2.
5. Install brass hose fitting into Port 2.
6. Install pipe plug into Port 1.
7. Connect carburetor gas hose to brass fitting.
8. Tighten all clamps and plugs.
9. Make sure fuel supply is of the proper pressure
and type for configuration.
10. Reverse the procedure to convert back to natural
gas.
Figure 1.8 — Reconfigure the Fuel System
PLUG
1.11 FUEL CONSUMPTION
Natural Gas:
% of Load
m3/hr
ft3/hr
LP Vapor:
% of Load
m3/hr
ft3/hr
Port 2
Port 1
FUEL HOSE
FUEL HOSE
BRASS HOSE
FITTING
OUT
PORT 1
BRASS HOSE
FITTING
HOUSING
PORTS
HOUSING
PORTS
25%
3.1
110.3
50%
5.9
209.0
75%
8.5
299.5
100%
11.0
387.0
25%
1.3
45.6
50%
2.4
86.4
75%
3.5
123.8
100%
4.5
160.0
PLUG
OUT
PORT 2
NG FUEL SYSTEM
LP FUEL SYSTEM
NOTE:
NOTE:
Fuel consumption is given at rated maximum
continuous power output when using natural gas
rated at 1000 Btu per cubic foot. LP gas is rated at
2520 Btu per cubic foot. Actual fuel consumption
obtained may vary depending on such variables as
applied load, ambient temperature, engine conditions and other environmental factors.
Port 1 is for NG only and Port 2 is for LP vapor
only. No provision for dual fuel has been made.
DANGER
injury or damage may occur if not con Serious
figured properly. Please consult an Authorized
Service Dealer with any questions.
7
Section 2 — Installation
Liquid-cooled 30 kW Generators
1.13 TORQUE SPECIFICATIONS
Cylinder Head ............................................ 15 (+ 90° + 90°) ft.lb.
Intake Manifold ................................................................ 13 ft.lb.
Exhaust Manifold ............................................................. 13 ft.lb.
1.14 ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the
factory. Use a high-quality detergent oil classified “For
Service CC, SD, SE, SF.” Detergent oils keep the engine
cleaner and reduce carbon deposits. Use oil having
the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil
change:
Temperature
Oil Grade (Recommended)
Above 80° F (27° C)
SAE 5W-20
32° to 80° F (-1° to 27° C)
SAE 5W-20
Below 32° F (0° C)
SAE 5W-20
NOTE:
Synthetic oil is highly recommended in any element
with temperatures above 90° F or below 30° F.
attempt to crank or start the engine before it
 Any
has been properly serviced with the recommended oil may result in an engine failure.
1.15 COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base
anti-freeze and half de-ionized water. Cooling system
capacity is about 12 U.S. quarts (11.4 liters). Use only
de-ionized water and only low silicate anti-freeze. If
desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant,
always add the recommended 50-50 mixture.
not use any chromate base rust inhibitor
 Do
with ethylene glycol base anti-freeze or chromiumhydroxide (“green slime”) forms and will
cause overheating. Engines that have been operated with a chromate base rust inhibitor must
be chemically cleaned before adding ethylene
glycol base anti-freeze. Using any high silicate
anti-freeze boosters or additives will also cause
overheating. It is also recommend that any soluble oil inhibitor is NOT USED for this equipment.
1.16 BEFORE INSTALLATION
Before installing this equipment, check the ratings
of both the generator and the transfer switch. Read
“Emergency Isolation Method” and “Total Circuit
Isolation Method” in Sections 2.5 and 2.6.
8
The generator’s rated wattage/amperage capacity
must be adequate to handle all electrical loads that
the unit will power. The critical (essential) loads may
need to be grouped together and wired into a separate “emergency” distribution panel.
This generator can be installed in conjunction with
an engineered “GTS” type transfer switch, if necessary.
The standard transfer switch has no sensing or controlling circuit boards. Instead, the generator control
console houses a “Printed Circuit Board Assembly”,
which controls all phases of operation, including
engine start up and load transfer.
2.1
STANDBY GENERATOR
INSTALLATION
DANGER
this generator to an electrical system
 Connecting
normally supplied by an electric utility shall be
by means of a transfer switch, so as to isolate
the electric system from the utility distribution
system when the generator is operating. Failure
to isolate the electric system by these means
will result in damage to the generator and may
also result in injury or death to utility workers
due to backfeed of electrical energy.
open bottom is used, the engine-generator
 Ifis an
to be installed over non-combustible materials and should be located such that combustible
materials are not capable of accumulating under
the generator set.
Only qualified, competent installation contractors
or electricians thoroughly familiar with applicable
codes, standards and regulations should install this
standby electric power system. The installation must
comply strictly with all codes, standards and regulations pertaining to the installation.
the system has been installed, do nothing
 After
that might render the installation in noncompliance with such codes, standards and regulations.
‹ 2.1.1
NFPA STANDARDS
The following published standards booklets pertaining to standby electric systems are available form
the National Fire Protection Association (NFPA),
Batterymarch Park, Quincy, MA 02269:
NOTE:
It is essential to use the latest version of any standard to ensure correct and current information.
Section 2 — Installation
Liquid-cooled 30 kW Generators
• NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL
SYSTEMS FOR HEALTH CARE FACILITIES.
• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND
USE OF PORTABLE FIRE EXTINGUISHERS.
‹ 2.1.2
OTHER PUBLISHED STANDARDS
In addition to NFPA standards, the following information pertaining to the installation and use of standby
electric systems is available:
NOTE:
It is essential to use the latest version of any standard to ensure correct and current information.
• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.
• ASAE
EP-364.2,
INSTALLATION
AND
MAINTENANCE OF FARM STANDBY ELECTRIC
POWER, available from the American Society
of Agricultural Engineers, 2950 Niles Road, St.
Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD
FOR CHIMNEYS, FIREPLACES AND VENTING
SYSTEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
2.2
GENERATOR LOCATION
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings into
the prevailing winds.
• Install the generator as close as possible to the
transfer switch. This reduces the length of wiring
and conduit.
• Install the generator as close as possible to
the fuel supply, to reduce the length of piping.
HOWEVER, REMEMBER THAT LAWS OR CODES
MAY REGULATE THE DISTANCE.
2.3
GENERATOR MOUNTING AND
SUPPORT
Retain the generator compartment to a concrete slab
with 1/4-inch masonry type anchor bolts. Be sure the
bolts are long enough to retain the compartment. The
slab should be at least six inches thick and should
extend beyond the enclosure to a distance of at least
three inches on all sides. See Section 6 for generator
major dimensions.
2.4
BASIC STANDBY ELECTRIC
SYSTEM
Figure 2.1 shows a schematic diagram of a basic
standby electric system. Both the UTILITY power
supply and the STANDBY (GENERATOR) output are
connected to an approved transfer switch. The transfer switch is required by electrical code and serves
the following functions:
• Allows the LOAD circuits to be connected to only
one power supply at a time.
• Prevents electrical backfeed between the generator
and the UTILITY power circuits.
Notice that both the STANDBY and the UTILITY
power supplies to the transfer switch are protected
against overload by a main line circuit breaker.
Figure 2.1 – Basic Standby Electric System
Install the generator set, in its protective enclosure
outdoors, where adequate cooling and ventilating air
always is available. Consider these factors:
• Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass,
snow, etc. If prevailing winds will cause blowing or
drifting, consider using a windbreak to protect the
unit.
• Install the generator on high ground where water
levels will not rise and endanger it.
• This genset must be installed on a level surface.
The base frame must be level within 1/2 inch all
around.
• Allow sufficient room on all sides of the generator
for maintenance and servicing. A good rule is to
allow five feet of space on all sides.
9
Section 2 — Installation
Liquid-cooled 30 kW Generators
2.5
EMERGENCY CIRCUIT ISOLATION
METHOD
Figure 2.2 – Generator Grounding Lug (typical)
This prevents overloading the generator by keeping
electrical loads below the wattage/amperage capacity
of the generator. If the generator can only power critical loads, within it’s wattage/amperage capacity, during utility power outages, use the emergency circuit
isolation method.
GROUNDING
LUG
Critical electrical loads are grouped together and
wired into a separate “Emergency Distribution Panel.”
Load circuits powered by that panel are within the
wattage/amperage capacity of the generator set. The
transfer switch must meet the following requirements:
• It must have an ampere rating equal to the total
amperage rating of the emergency distribution
panel circuit.
• Have it installed between the building’s main distribution panel and the emergency distribution
panel.
2.6
TOTAL CIRCUIT ISOLATION
METHOD
When a generator capable of powering all electrical
loads in the circuit is to be installed, use the “Total
Circuit Isolation Method.” It is possible for the generator to be overloaded when this isolation method is
employed. The following apply to the transfer switch
in this type of system.
• Ampere rating of the transfer switch must equal
the ampere rating of the normal incoming utility
service.
• The transfer switch is installed between the utility service entrance and the building distribution
panel.
2.7
GROUNDING THE GENERATOR
The National Electrical Code requires the frame and
external electrically conductive parts of this equipment to be properly connected to an approved earth
ground and/or grounding rods. For that purpose, a
GROUND LUG (Figure 2.2) is provided on the generator mounting base. Consult a qualified electrician
for grounding requirements in the area. Grounding
procedures must meet local regulations.
DANGER
not connect the ground wire to any pipe
 Do
that carries a flammable or explosive substance
– FIRE or an EXPLOSION may result.
Proper grounding helps protect personnel against
electrical shock in the event of a ground fault condition in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices.
2.8
GENERATOR AC NEUTRAL
CONNECTIONS
The manufacturer uses an UNGROUNDED AC neutral. Grounding is recommended only at the main
service entrance. If the neutral wire is grounded and
one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field. The actual result depends
on the electrical characteristics of the particular
installed generator.
to connect the generator neutral proper Failure
ly will result in unbalanced line-to-neutral voltages. Resulting high voltages will cause equipment damage.
2.9
TRANSFER SWITCH SIGNAL
CONNECTIONS
‹ 2.9.1 PRE-PACKAGED ATS
If the generator is to be installed with a pre-packaged
(non-control board based) transfer switch, it is necessary to connect the control wires to the generator
and set position two of the four-position dip switch
to OFF.
Setting switch two to OFF allows the control PCB to
perform the ATS control functions.
10
Section 2 — Installation
Liquid-cooled 30 kW Generators
Control system interconnections consist of N1 and
N2, and leads 23 and 194. Control system interconnection leads must be run in a conduit that is separate from the AC power lead. Recommended wire
gauge sizes for this wiring depends on the length of
the wire, as recommended below:
MAXIMUM WIRE LENGTH
460 feet (140m)
461 to 730 feet (223m)
731 to 1,160 feet (354m)
1,161 to 1,850 feet (565m)
RECOMMENDED WIRE
SIZE
No. 18 AWG.
No. 16 AWG.
No. 14 AWG.
No. 12 AWG.
‹ 2.9.2 GTS-TYPE ATS
If the generator is to be installed with an automatic
transfer switch, such as an engineered GTS-type
switch, it is necessary to connect the two-wire start
control system.
Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection,
which is located in the middle, on the bottom, inside
the control panel. Match wires 178 and 183 in the
transfer switch to 178 and 183 on the terminal strip
in the control panel. The conductors for the twowire start circuit must be in their own conduit. (See
Section 3.1 for further explanation.)
2.10 BATTERY INSTALLATION
DANGER
generators installed with automatic
 Standby
transfer switches will crank and start automatically when NORMAL (UTILITY) source voltage is
removed or is below an acceptable preset level.
To prevent such automatic start-up and possible
injury to personnel, ensure that the 15A and
4A fuses are removed from the control console,
the AUTO/OFF/MANUAL switch is set to OFF,
and the utility supply to the battery charger is
removed before removing or connecting battery
cables.
batteries give off explosive hydrogen
 Storage
gas. This gas can form an explosive mixture
around the battery for several hours after charging. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can shatter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing
tools or equipment near the battery.
electrolyte fluid is an extremely caus Battery
tic sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
electrolyte is to be washed down with
 Spilled
an acid neutralizing agent. A common practice
is to use a solution of one pound (500 grams)
bicarbonate of soda to one gallon (4 liters) of
water. The bicarbonate of soda solution is to be
added until the evidence of reaction (foaming)
has ceased. The resulting liquid is to be flushed
with water and the area dried.
not dispose of the battery in a fire. The
 Do
battery is capable of exploding.
not open or mutilate the battery. Released
 Do
electrolyte can be toxic and harmful to the skin
and eyes.
battery represents a risk of high short circuit
 The
current. When working on the battery, always
remove watches, rings or other metal objects,
and only use tools that have insulated handles.
When replacing batteries, use the same number
and type of battery. The recommended batteries are
Group 26, 12V negative ground 525 CCA/75 AH minimum capacity, or Group 27F, 12V negative ground
600 CCA/90 AH minimum capacity. All batteries
must be at 100 percent state-of-charge before they
are installed on the generator.
When using maintenance-free batteries, it is not
necessary to check the specific gravity or electrolyte
level. Have these procedures performed at the intervals specified in Section 4, “Maintenance.” A negative ground system is used. Battery connections are
shown on the wiring diagrams. Make sure all batteries are correctly connected and terminals are tight.
Observe battery polarity when connecting batteries to
the generator set.
NOTE:
Damage will result if the battery connections are
made in reverse.
2.11 PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for
use by a competent, qualified installation contractor.
Be sure to read the “Safety Rules” on Pages 2 and 3,
as well as all other safety information in this manual,
before attempting to operate this (and related) equipment.
11
Section 3 — Operation
Liquid-cooled 30 kW Generators
‹ 2.11.1 PRIOR TO INITIAL START-UP
‹ 2.11.6 BELT TENSION
to initially starting the generator, it must
 Prior
be properly prepared for use. Any attempt to
Check-the engine-fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm).
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant, fuel,
etc.) may result in an engine failure.
Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service
intervals, please refer to Section 4, “Maintenance.”
‹ 2.11.2 TRANSFER SWITCH
If this generator is used to supply power to any electrical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems (for additional information, see the applicable
transfer switch manual for this unit). The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
‹ 2.11.3 FUEL SYSTEM
Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and (b)
is properly purged and leak tested according to code.
No fuel leakage is permitted. See “Specifications”
(Section 1.10) for more information.
‹ 2.11.4 GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
(Section 1.10) and “Engine Oil Recommendations”
(Section 1.14).
NOTE:
‹ 2.11.7 ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground and/or ground rod.
Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.
Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear
of any moving generator set components.
3.1
USING AN ENGINEERED “GTS”
TRANSFER SWITCH
When required, the pre-packaged standby generator
can be installed with an engineered “GTS” type automatic transfer switch.
In this application, the GTS is responsible for utility
sensing, weekly exercising, and load transferring.
Position two of the four-position dip switch is used to
turn over this control to the GTS.
Pos2 ON — GTS Application
• The generator’s control board will NOT monitor
utility.
• The control board will NOT perform a weekly
exercise. (The five red LEDs will not flash in this
mode.)
• The control board will NOT activate the transfer
output.
• The control board WILL monitor all engine conditions and shut down on all the faults listed in this
document.
Pos2 OFF — ATS Application
This engine is shipped from the manufacturer
with 5W-20 oil. This oil should be changed after
30 hours of operation.
• The generator’s control board will perform all of
the automatic features listed in this document.
• The two-wire start connections should NOT be
used.
‹ 2.11.5 ENGINE COOLANT
GTS Mode Operation
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
(Section 1.10) and “Coolant” (Section 1.15).
When in GTS mode, the generator’s control board
will respond as follows based on the AUTO/OFF/
MANUAL switch position.
12
OFF — The generator will not start and run in this
position.
Section 3 - Operation
Liquid-cooled 30 kW Generators
MANUAL — The control board will start and run
the generator whenever the switch is in the manual
position.
AUTO — The control board will monitor the twowire start circuit. When a two-wire start is issued the
control board will immediately start and run the generator. Whe the two-wire start is removed the control
board will immediately stop the generator.
NOTE:
If the generator is installed in conjunction with an
engineered GTS type transfer switch, refer to the
applicable transfer switch manual for exact operating parameters and timing sequences.
3.2
CONTROL CONSOLE
COMPONENTS
The components of a home standby generator control
console (Figure 3.1) are as follows:
‹ 3.2.1 AUTO/OFF/MANUAL SWITCH
Use this three-position switch as follows:
• Set the switch to AUTO for fully automatic operation. See “Automatic Operation” (Section 3.6).
• Set switch to MANUAL position to crank and start
the generator engine.
• Set switch to OFF position to shut down an operating engine. With OFF selected, operation will not
be possible.
Figure 3.1 - Home Standby Generator Panel
DANGER
switch set to AUTO, engine can crank and
 With
start suddenly without warning. Such automatic
start up normally occurs when utility source
voltage drops below a pre-set level. To prevent
possible injury that might be caused by such
sudden starts, set AUTO/OFF/MANUAL switch
to OFF before working on or around the unit.
Then, place a “DO NOT OPERATE” tag on control
console.
‹ 3.2.2 FAULT INDICATOR LED
This LED goes ON when one or more of the following
engine faults occurs and when engine shuts down.
• Low Oil Pressure
• Overcrank
• Low Battery
• Overspeed/RPM Sensor Loss
• High Coolant Temperature/Low Coolant Level
See Section 1.7 for further explanation of engine protection functions.
‹ 3.2.3 15 AMP FUSE
Fuse protects the control console’s DC control circuit
against electrical overload. If the fuse has melted
open because of an overload, engine cranking and
startup cannot occur. If the fuse needs to be replaced,
use only an identical 15-amp replacement fuse. (Type
AGC)
‹ 3.2.4 4.0 AMP INLINE FUSE
LED INDICATORS:
FLASHING GREEN LED = NO UTILITY SENSE
5 FLASHING RED LED'S = EXERCISER NOT SET
(IN AUTO MODE ONLY) SOLID GREEN LED = SYSTEM READY, UTILITY POWER ON
RED LED'S = INDIVIDUAL FAULT
(SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS)
F
F
F
OVER CRANK
E
US
RED LED
NOTE:
E
US
AUTO
OFF
OFF
SET
EXECISER
TIME
SWITCH
4A FUSE
BATTERY
CHARGER
ON
SET
EXERCISE
TIME
This fuse protects the battery charger against electrical overload. If the fuse needs to be replaced, use only
an identical 4 amp replacement fuse (type AG).
MANUAL
GREEN LED
TO SET EXERCISER TIME
This fuse will not remove the + battery input
power from the PCB when it opens. This means
the exercise timer will not be reset.
1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.
‹ 3.2.5 SET EXERCISE TIME SWITCH
0E7194
AUTO/OFF/MANUAL
SWITCH
15A FUSE
MAIN
POWER
This switch allows programming the generator to
start and exercise automatically. “See Weekly Exercise
Cycle.”
‹ 3.2.6 SYSTEM READY LED
The System Ready LED (green) has two main proposes. First, the LED will be ON when the AUTO/
OFF/MANUAL switch is in the AUTO position, utility
is present, and there are no system alarms. This ON
state indicates the system is fully ready for automatic
operation.
13
Section 3 — Operation
Liquid-cooled 30 kW Generators
The system ready LED will be OFF when the switch
is in the manual or OFF positions.
Figure 3.2 — Engine Governor Adjustment
The system ready LED is also used to indicate the
presence of utility sensing at the PCB when the switch
is either in the AUTO or MANUAL modes. The LED
will flash at the rate of 1/2 second on, 1/2 second off
if the utility sensing level is below the transfer back
threshold.
R44
LED1
C27
Q2
2
C9
J2
C26
U7
C4
D10
C21
This secondary function is only available with dip
switch two in the OFF position (standard ATS application).
C30
C2
RL1
RL2
R1
MANUAL TRANSFER AND
START-UP
R25
3.3
D17
R49
U1
To transfer electrical loads to the Standby
(EMERGENCY) power source side and start the
engine manually, refer to the Owner’s Manual of the
particular transfer switch.
3.4
ENGINE GOVERNOR
ADJUSTMENTS
Engine speed governing is also controlled by the
engine control board. Connector J2 on the engine
control board interfaces with a governor driver module and the Bosch throttle body. The engine governor has been set by the factory during final testing
of the generator and, in most cases, should not be
adjusted.
If, however, adjustments are necessary, or a new
engine control board is installed in the generator, the
following procedure should be followed (Figure 3.2):
1. Set all three potentiometers (pots) fully counterclockwise.
2. Under no load condition, increase the GAIN pot
as much as possible without causing instability.
3. Apply 1/4, 1/2, 3/4 and full load to the unit.
Decrease the GAIN pot if there is instability at any
load point.
4. Under full load condition, increase the stability
pot until the unit returns to 60 Hertz (or 50 Hertz
in 50 Hertz applications).
5. Reduce load to 3/4, 1/2, 1/4 and no load. Decrease
the stability pot if there is instability at any load
point.
6. Adjust differential pot to make the recovery to
load changes even faster and minimize load
change undershoot and overshoot. If it is set too
high it may introduce oscillations at some load.
It can be set to zero (full CCW) if a small amount
causes oscillations at some load.
14
R48
J1
L3
D19
.VER 6094E0 #BCP
DIFFERENTIAL
STABILITY
3.5
DIP SWITCH
4
3
2
1
UNUSED
GTS/ATS
50/60 HZ
POSITION 1
50/60 HZ
ON = 50 HZ
OFF = 60 HZ
POSITION 2
GTS/ATS Select
ON = GTS
OFF = ATS (standard mode)
RETRANSFER AND SHUTDOWN
When utility power source voltage has been restored,
electrical loads may be transferred back to that
source and the generator can be shut down as follows:
• Verify that UTILITY power supply voltage to the
transfer switch has been positively turned OFF,
using whatever means provided (such as utility
main line circuit breaker).
• Set the generator’s main circuit breaker to its OFF
or OPEN position.
• Let the generator engine run at no-load for a few
minutes, to stabilize internal unit temperatures.
• On the generator console, set the AUTO/OFF/
MANUAL switch to OFF. Wait for engine to come to
a complete stop.
• For transfer to utility position, refer to the Owner’s
Manual of the particular transfer switch.
• Turn on the UTILITY power supply to the transfer
switch, using whatever means provided (such as
a utility main line circuit breaker). The UTILITY
power source now powers the loads.
3.6
AUTOMATIC OPERATION
To set the system for fully automatic operation, proceed as follows:
• Check that load circuits are connected to the
utility power supply.
• Set the AUTO/OFF/MANUAL switch to its AUTO
position.
• Set the generator main circuit breaker to its ON or
CLOSED position.
Section 4 — Maintenance
Liquid-cooled 30 kW Generators
3.7
WEEKLY EXERCISE CYCLE
4.1
The engine control board will start and run the generator once every seven days for approximately 12
minutes. If utility should fail during this exercise
period, the engine control board will transfer the load
to the generator output and continue to run until utility returns.
On the day, and at the time of day chosen for the
generator to exercise, set the weekly exercise cycle
as follows:
1. Place the AUTO/OFF/MANUAL switch in the
AUTO position.
2. Press and hold the “Set Exercise” switch for three
seconds, then release.
At this time all five red LEDs will flash for approximately 10 seconds, then the engine will start and run
for it’s 12 minute exercise period, then shut down.
The generator will now start and run each week at
the same time.
If DC power to the control board is lost, the weekly
exercise setting will be lost. This is indicated by all
five red LEDs continually flashing. In this state the
generator will still start and run in manual mode, or
automatically start and run if UTILITY is lost while in
Auto mode, but it will not perform a weekly exercise
cycle.
If a failure occurs while running in this mode, the five
red LEDs will stop flashing, the individual fault LED
will turn on and the engine will shut down. Once the
AUTO/OFF/MANUAL switch has been switch to OFF,
the individual fault LED will turn OFF and the five
red LEDs will begin flashing to show exercise has still
not been set.
F
E
E
FUSE
15A
MAIN
US
‹ EVERY THREE MONTHS
1.
2.
3.
4.
5.
6.
Check battery state of charge and condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.
‹ ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).
‹ ONCE ANNUALLY
1. Test engine governor. Adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.
‹ FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. (After initial
change, service engine oil and filter at 150 operating hours or 6 months, whichever comes first.)
2. Retorque cylinder head. (See Torque Specs,
Section 1.13.)
3. Retorque intake and exhaust manifold. (See
Torque Specs, Section 1.13.)
‹ EVERY 500 OPERATING HOURS
1. Service air cleaner.
2. Check starter.
3. Check engine DC alternator.
4.2
COOLING SYSTEM
Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.
F US
US
F USE
FUSE
4A
BAT.
CHARGER
F SE
F
Figure 3.2 - “Set Exercise” Switch
MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES
US
AUTO
OFF
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down. (See Section 6 for installation drawings
and vent locations.)
OFF
ON
SET
EXERCISE
TIME
MANUAL
exhaust system parts from this product get
 The
extremely hot and remain hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
15
Section 4 — Maintenance
Liquid-cooled 30 kW Generators
4.3
OVERLOAD PROTECTION FOR
ENGINE DC ELECTRICAL SYSTEM
Engine cranking, start up and running are controlled
by a solid state Engine Controller circuit board.
Battery voltage is delivered to that circuit board via
a 15 amp fuse. These overcurrent protection devices
will open if the circuit is overloaded.
a circuit breaker opens or a fuse element
 Ifmelts,
find the cause of the overload before
resetting the circuit breaker or replacing the
fuse.
4.4
CHECKING FLUID LEVELS
‹ 4.4.3 ENGINE COOLANT
Check coolant level in coolant recovery bottle. See
Specifications, Section 1.10.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap to make
sure the coolant recovery system is functioning
properly. Coolant should be at bottom of radiator
filler neck. If coolant level is low, inspect gasket in
radiator pressure cap. Replace cap, if necessary.
To have pressure cap tested, contact an Authorized
Service Dealer. Inspect cooling system and coolant
recovery system for leaks.
4.5
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
‹ 4.4.1 CHECK ENGINE OIL
‹ 4.5.1 CHECK ENGINE OIL LEVEL
Check engine crankcase oil level (Figure 4.1) at least
every 20 hours of operation, or prior to use.
Refer to “Checking Fluid Levels” in Section 4.4.
• Remove oil dipstick and wipe dry with a clean, lintfree cloth.
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark, remove
oil fill cap. Add the recommended oil to bring oil
level up to the FULL mark. DO NOT FILL ABOVE
THE “FULL” MARK. See Section 1.14 for recommended oils.
Figure 4.1 - Oil Dipstick and Oil Fill Cap
‹ 4.5.2 CHECK BATTERY
• Check battery fluid level each week as outlined
under “Check Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as
necessary.
‹ 4.5.3 EXERCISE SYSTEM
Start the generator engine at least once every seven
days and let it run at least 20 minutes. See Section
3.6, “Weekly Exercise Cycle”.
‹ 4.5.4 INSPECT COOLING SYSTEM
OIL
DIPSTICK
• Inspect engine cooling system at least once each
month.
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
OIL
FILL
‹ 4.5.5 CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels” in Section 4.4.
‹ 4.5.6 PERFORM VISUAL INSPECTION
Complete a thorough visual inspection of the entire
engine-generator monthly. Look for obvious damage,
loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
‹ 4.4.2 BATTERY FLUID
Check battery electrolyte fluid at least once weekly.
Fluid should cover separators in all battery cells. If
fluid level is low, add distilled water to cover tops of
separators. DO NOT USE TAP WATER IN BATTERY.
16
‹ 4.5.7 INSPECT EXHAUST SYSTEM
Inspect the exhaust system at least once every three
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security,
damage.
Section 4 — Maintenance
Liquid-cooled 30 kW Generators
‹ 4.5.8 CHECK FAN BELT
Figure 4.2 - Oil Filter
• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8
to 5/8 inch. Adjust belt tension as required.
‹ 4.5.9 INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
DANGER
not attempt to adjust the governor. Only
 Do
qualified service facilities should adjust the
governor. Excessively high operating speeds
are dangerous and increase the risk of personal
injury. Low speeds impose a heavy load on the
engine when adequate engine power is not
available and may shorten engine life. Correct
rated frequency and voltage are supplied only
at the proper governed speed. Some connected
electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified
service technicians should adjust the governed
speed.
‹ 4.5.10 CHANGING ENGINE OIL
Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies.
Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down
and drain immediately as follows:
1. Remove OIL DRAIN HOSE from its retaining
clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain
oil completely into suitable container.
3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP, and re-install into its retaining
clip.
4. Turn OIL FILTER (Figure 4.2) counterclockwise
and remove. Dispose of old filter.
5. Apply light coating of new engine oil to seal of new
oil filter.-Install FILTER and tighten by hand only.
DO NOT OVERTIGHTEN.
6. Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity
is 4.0 U.S. quarts (3.8 liters).
OIL FILTER
refilling the crankcase with oil, always
 After
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.
‹ 4.5.11 CHANGING THE ENGINE AIR CLEANER
To replace the engine air cleaner, (part number
059402), remove the air cleaner cover and replace
the air filter making sure it is positioned properly
before reattaching the cover (Figure 4.3).
Figure 4.3 – Engine Air Cleaner
See the “Service Schedule,” Section 6, for air cleaner
maintenance.
17
Section 4 — Maintenance
Liquid-cooled 30 kW Generators
‹ 4.5.12 SPARK PLUGS
Reset the spark plug gap or replace the spark plugs
as necessary. See Section 6.
1. Clean the area around the base of the spark plugs
to keep dirt and debris out of the engine. Clean
by scraping or washing using a wire brush and
commercial solvent. Do not blast the spark plugs
to clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is
questionable. See the “Service Schedule,” Section
6, for recommended inspection.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 1.06-1.16 mm (0.0420.046 inch) by carefully bending the ground electrode (Figure 4.4).
Figure 4.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 1.06-1.16 mm
(0.042-0.046 inch)
‹ 4.5.13 COOLANT CHANGE
Every year, have Authorized Service Facility drain, flush
and refill the cooling system. See SPECIFICATIONS
(Section 1.10) for cooling system recommendations.
4.6
MISCELLANEOUS MAINTENANCE
‹ 4.6.1 CLEANING THE GENERATOR
Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation
resistance.
Periodically clean generator exterior surfaces. A soft
brush may be used to loosen caked on dirt. Use a
vacuum system or dry, low pressure air to remove
any accumulations of dirt. The generator is housed
inside an all-weather enclosure, clean the enclosure
with a soft, damp cloth or sponge and water.
Once each year, have the generator cleaned and
inspected by an Authorized Service Dealer. That
dealer will use dry, low pressure air to clean internal
windings. Parts inside the control console should be
cleaned and inspected at this time as well.
18
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
‹ 4.6.2 BATTERY
All lead-acid storage batteries discharge when not in
use. Refer to specific instructions and warnings that
accompany the battery. If such information is not
available, observe the following precautions when
handling a battery:
• DO NOT use jumper cables and a booster battery
to crank or start the generator engine.
• DO NOT recharge a weak battery while it is
installed in the generator. Remove battery from
generator and recharge in a well-ventilated area,
away from fuel vapors, sparks, heat or flames.
• Battery electrolyte fluid is an extremely caustic
sulfuric solution that can cause severe burns. DO
NOT permit fluid to contact eyes, skin, clothing,
painted surfaces, wiring insulation, etc. If any battery fluid is spilled, flush the affected area with
clear water immediately.
• Always wear safety glasses, rubber apron and
gloves when handling a battery.
• Batteries give off explosive hydrogen gas while
charging. The gas can form an explosive mixture
around the battery for several hours after charging.
Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
causing blindness or other serious injury.
‹ 4.6.3 BATTERY MAINTENANCE
The battery should be inspected per the “Service
Schedule,” Section 6. The following procedure should
be followed for inspection:
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTERIES.
3. Have the state of charge and condition checked.
This should be done with an automotive-type battery hydrometer.
Section 4 — Maintenance
Liquid-cooled 30 kW Generators
DANGER

Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after charging. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can shatter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing
tools or equipment near the battery.
electrolyte fluid is an extremely caus Battery
tic sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If the fluid is spilled, flush
the affected area immediately with clear water.
‹ 4.6.4 BATTERY REPLACEMENT
When replacing batteries, use the same number and
the type of battery that follows:
BCI Group No.
26/26R
27
CCA
525 @ 0 deg. F
600 @ 0 deg. F
NOTE:
The BCI number should be located directly
on the battery.
‹ PERIODIC REPLACEMENT PARTS
Part Name
Oil Filter
Radiator Cap
Air Cleaner
Spark Plug
Part Number
# 0E7180
# 046627
# 0C8127
# 0E7079
electrolyte is to be washed down with
 Spilled
an acid neutralizing agent. A common practice
is to use a solution of one pound (500 grams)
bicarbonate of soda to one gallon (4 liters) of
water. The bicarbonate of soda solution is to be
added until the evidence of reaction (foaming)
has ceased. The resulting liquid is to be flushed
with water and the area dried.
not use any jumper cables or booster battery
 Do
to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.
that the 15A and 4A fuses are removed
 Ensure
from the control console, the AUTO/OFF/
MANUAL switch is set to OFF, and the utility
supply to the battery charger is removed before
removing or connecting battery cables. If the
switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery
cables are connected.
sure the UTILITY power supply to the battery
 Be
charger is turned off, or sparking may occur at
the battery posts as the cables are attached and
cause an explosion.
19
Section 4 — Maintenance
Liquid-cooled 30 kW Generators
4.7
SCHEDULED MAINTENANCE
The following is a recommended maintenance schedule for small standby and residential generator sets. The
established intervals in the schedule are the maximum recommended when the unit is used in an average service
application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to
determine the next required maintenance interval.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to ensure it is ready to operate when required and to identify any potential problem areas.
Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 manhours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel
AUTO-OFF-MANUAL switch to the “OFF” position.
• Remove the control panel 15A and 4A fuses.
• Turn off the battery charger.
• Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.
2 A break-in service inspection of the generator set to ensure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of
the unit and requires approximately 2.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
3 An operational inspection of the generator set to ensure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5
man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
4 A mid-level inspection of the generator set to ensure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0
man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
20
Section 4 — Maintenance
Liquid-cooled 30 kW Generators
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Task
Comp.
(DateInitials)
Required
to be done
3 months/
Break-in
30 hrs.
Level 3
Task
Comp.
(DateInitials)
Required
to be done
Semiannually/
50 hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Task
Comp.
(DateInitials)
1. Disable the unit from
operating per the first page
warning.
2. Check the engine oil level.
Adjust as necessary.
3. Check the engine coolant
level. Adjust as necessary.
4. Check the engine coolant
thermal protection level.
Correct as necessary.
5. Check the natural gas
delivery system on gas
engine driven units.
Tighten connections as
necessary.
6. Check the air inlets and
outlets for debris. Clean as
necessary.
7. Check the battery
electrolyte level if
accessible. Adjust as
necessary.
8. Check the battery posts,
cables, and charger for
loose connections,
corrosion, and proper
operation. Correct as
necessary.
9. Check the unit wiring for
loose connections,
corrosion, and damage.
Correct as necessary.
10. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
11. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
12. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.
21
Section 4 — Maintenance
Liquid-cooled 30 kW Generators
Maintenance
Tasks
13. Initiate an automatic start
and transfer of the unit to
site load and exercise it for
at least 1 hour looking for
leaks, loose connections
or components, and
abnormal operating
conditions. Correct as
necessary.
14. Start and exercise the unit
at full rated load (use a
load bank if the site load is
not enough) for at least 2
hours looking for leaks,
loose connections or
components, and abnormal
operating conditions.
Correct as necessary.
15. Change the engine oil.
16. Replace the engine oil
filter(s).
17. Replace the engine air
filter(s).
18. Replace the engine fuel
filter(s) on diesel engine
driven units and re-prime
the fuel system.
19. Check the engine spark
plugs on gas engine driven
units. Clean and re-gap or
replace as necessary.
20. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
21. Return the unit to standby
setup for operation when
required.
22
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Task
Comp.
(DateInitials)
Required
to be done
3 months/
Break-in
30 hrs.
Level 3
Task
Comp.
(DateInitials)
Required
to be done
Semiannually/
50 hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Task
Comp.
(DateInitials)
Section 5 — Troubleshooting
Liquid-cooled 30 kW Generators
TROUBLESHOOTING POINTS
PROBLEM
CAUSE
CORRECTION
Engine won’t crank.
1. 15 amp fuse blown.
2. Loose or corroded or defective
battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 4 amp fuse blown.
1. Replace fuse.
2. Tighten, clean or replace
battery cables as necessary.
3. Replace contactor.
4. Replace starter motor.
5. Remove, change or replace battery.
6. Replace fuse.
Engine cranks, but won't start
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14 from Engine Control
circuit board.
4. Spark plugs defective.
1. Replenish fuel.
2. Replace solenoid.
3. Reconnect wire.
1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
1. Clean or replace as needed.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
Engine starts, then shuts down.
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.
AUTO/OFF/MANUAL Switch at,
OFF engine continues to run
1. Defective AUTO/OFF/MANUAL switch
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board
3. Replace board.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Engine starts hard, runs rough.
No AC output from generator.
Engine oil level is low.
Engine is overheated.
Defective Low Oil Pressure Switch
Defective Coolant Temperature Switch
Defective Control Module circuit board.
Coolant Level is Low.
Defective Low Coolant Level Switch
Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
Thermal circuit breaker open.
4. Clean, regap or replace plugs.
Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.
Replace switch.
Replace board.
Repair leak - Add coolant.
Replace Switch.
1. Replace switch.
2. Reconnect/close wire.
Reset to ON or CLOSED.
Reset and replace, if necessary.
Set to GENERATOR position.
Contact an Authorized facility.
Auto-reset - Wait 5 min. and
attempt restart.
23
Section 6 - Notes
Liquid-cooled 30 kW Generators
24
Section 7 — Installation Diagram
Liquid-cooled 30 kW Generators
Installation Diagram — Drawing No. 0E8695
25
Section 8 - Electrical Data
Liquid-cooled 30 kW Generators
Wiring Diagram — Engine — Drawing No. 0E6199-F
2
CB2
16
1
AVR 2
3
4
5
6
14
0
0
TB1
16
16
1
3
6
N2
N1
F1
BC1
194
178
178
15
13
13
14
4
5
11
6
UTILITY FROM T/SW
UTILITY FROM T/SW
TRANSFER RELAY COIL
TRANSFER RELAY COIL
C - REMOTE START
NO - REMOTE START
IC
11
44
1
4
2
5
6
55
66
44
NB
NEUTRAL
TRANSFER SWITCH
AUTOMATIC VOLTAGE REGULATOR
BRUSH ASSEMLY (GENERATOR)
BATTERY CHARGER
BULKHEAD CONNECTOR 1 (ENGINE)
CIRCUIT BREAKER (OUTPUT)
CIRCUIT BREAKER (EXCITATION)
DIODE [FIELD BOOST]
FUSE, BAT. POWER (15A AGC TYPE)
6
CB1
CUSTOMER CONNECTION
LEGEND:
AVR BA B/C BC1 CB1 CB2 D1 F1 26
7
4
5
194
F2
8
1
2
183
178
N1
N2
23
13A
TR1
2a
15
16
225A
224A
178
178
183
1a
1 2
1 2 3
2b
55
0
0
0
4
4
N2
N1
14A
15E
15
14
SW1
16
14
13
13A
0
B/C
14
14
225
224
239
15A
15
1
3
3
OA
1b
RL1
D1
TR2
16
16
85
2
2
225
224
13A
1
0
55
14
1
0
0
14
162
1
162
11
4
44
6
55
6
44
4
11
2
1
NOTE:
SIZE (AWG)
ALL WIRES ARE 18 AWG 300
VOLT UL LISTED UNLESS
OTHERWISE NOTED AS SHOWN:
6
6
6
44
11
22
33
BA
STATOR
14
16
16
23
66
LEGEND {CONT.]:
F2 FUSE, B/C (4A AGC TYPE)
ICT INTERCONNECT. TERMINAL BLOCK
NB NEUTRAL BLOCK
RL1 RELAY 1
SW1 AUTO/OFF/MANUAL SWITCH
SW2 SET EXERCISER SWITCH
TB1 TERMINAL BLOCK 1
TR1 TRANSFORMER 1 (56 VA 240/16 VAC)
TR2 TRANSFORMER 2 (6 VA 240/16 VAC)
0
0
0
0A
13
14A
15A
15E
14
224
225
239
1
2
3
4
5
6
7
8
9
10
11
12
23
66
Section 8 - Electrical Data
Liquid-cooled 30 kW Generators
Wiring Diagram — Engine — Drawing No. 0E6199-F
NOTE:
SIZE (AWG)
ALL WIRES ARE 18 AWG 300
VOLT UL LISTED UNLESS
OTHERWISE NOTED AS SHOWN:
PCB J2
767
765
769
766
768
0
N/C
14
10
16
16
16
PCB J1
NC
LEGEND:
ALT BAT C1 CC DEG FS GND1GND2GOV -
14
14
14
0
765
766
14
766
765
767
770
771
768
767
769
BAT
15E
85
14A
225
66
4
10
10
13
0
0
C1
ALT
16
0
0A
0
14
16
FS
771
767
765
770
N/C
766
SM
0
0
14
0
0
GND1
16
16
0
14
14
0
449
449
14
0
1
2
3
4
5
6
16
16
16
16
IM
1
4
2
6
3
5
IC
3
2 5
1
16
85
85
BLK
RED
1
2
3
4
5
6
7
8
9
10
11
12
GOV
+
-
4
4
1
23
66
16
239
0
0
0
0A
13
14A
15A
15E
14
224
225
239
16
10
10
4
16
13
13
1
1
2
3
4
5
6
7
8
9
10
11
12
56
86
15A
23
224
0
GND2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DEG
JB
10
10
14
CC
13
13
13
56
0
16
1
2
3
4
5
6
7
8
HCT
WLS
86
0
0
23
66
D.C. CHARGE ALTERNATOR
12VDC BATTERY
CONNECTOR 1 (ENGINE)
STARTER CONTACTOR
DRIVER ELEC. GOVERNOR
FUEL SOLENOID
GROUND (SENSING/LOW AMP)
GROUND (POWER/HIGH AMP)
ELEC. GOVERNOR ACTUATOR
LEGEND [CONT.]:
HCT HIGH COOLANT TEMP SWITCH
IC IGNITION COIL
IM IGNITION MODULE (ON DISTRIBUTOR)
J-1 JUNCTION 1 (ON PCB)
J-2 JUNCTION 2 (ON PCB)
JB JUNCTION BLOCK (RUN POWER)
LOS LOW OIL PRESSURE SWITCH
SM STARTER MOTOR
WLS COOLANT LEVEL SWITCH
27
Section 8 - Electrical Data
Liquid-cooled 30 kW Generators
Electrical Schematic — Engine — Drawing No. 0E6200-B
ALTERNATOR ROTOR
ALTERNATOR STATOR
AUTOMATIC VOLTAGE REGULATOR
BRUSH ASSEMLY (GENERATOR)
BATTERY CHARGER
BATTERY CHARGE WINDING
CIRCUIT BREAKER (OUTPUT)
CIRCUIT BREAKER (EXCITATION)
DIODE [FIELD BOOST]
DISPLACED PHASE EXCITATION
LEGEND {CONT.]:
F1 FUSE, BAT. POWER (15A AGC TYPE)
F2 FUSE, B/C (4A AGC TYPE)
ICT TERMINAL BLOCK, INTERCONNECT.
NB NEUTRAL BLOCK
RL1 RELAY 1
SW1 SWITCH, AUTO/OFF/MANUAL
SW2 SWITCH, SET EXERCISER
TRANSFORMER 1 (56 VA 240/16 VAC)
TR1 TR2 TRANSFORMER 2 (6 VA 240/16 VAC)
66
0
RL1
14A
30
85
0
86
LEGEND:
AR AS AVR BA B/C BCW CB1 CB2 D1 DPE -
14
66
87
55
15
15
14
55
66
14
BCW
14
F2
1
1
2
3
AVR
4
5
6
224A
D1
AR
4
4
6
5
5
6
2
4
2
1 2
13
66
23
224
225
44
CB1
00
NB
CUSTOMER CONNECTION
120/240V 1-PHASE
E3
N1
N2
23
194
183
178
33
N2
23
15E
15
N1
TR2
TRANSFER SWITCH
CONNECTION
SW2
1
23
194
183
178
AS
22
TR1
N2
N1
N1
N2
28
15
15
225A
162
11
44
E1
F1
1 2 3
CB2
DPE
11
13
ICT
15
15A
178
15
194
183
178
1
2
4
5
3
6
2
2a
239
SW1
IN OFF POSITION
SHOWN
0
0
0
0A
13
14A
15A
15E
14
224
225
239
1
2
3
4
5
6
7
8
9
10
11
12
BULKHEAD CONNECTOR (BC1)
BA 1
13A
0A
Section 8 - Electrical Data
Liquid-cooled 30 kW Generators
Electrical Schematic — Engine — Drawing No. 0E6200-B
0
0
86
WLS
LOS
HCT
85
FS
0
CC
56
13
CC
12V BATTERY
)+(
(-)
RED
16
13
56
86
15A
23
224
0
239
15E
85
14A
225
66
J1-1
J1-2
J1-3
J1-4
J1-5
J1-6
J1-7
J1-8
J1-9
J1-10
J1-11
J1-12
J1-13
J1-14
ALT
PCB
J2-1
J2-2
J2-3
J2-4
J2-5
J2-6
J2-7
J2-8
GOV
CONNECTOR (C1)
1
2
3
4
5
6
7
8
9
10
11
12
0
0
0
0A
13
14A
15A
15E
14
224
225
239
LEGEND:
ALT C1 CC DEG FS GOV HCT -
BLACK
SC
13
SM
16
SC
14
1
2
3
4
5
6
66
23
0
771
767
765
770
N/C
766
D.C. CHARGE ALTERNATOR
CONNECTOR 1 (ENGINE)
CRANKING CONTACTOR
DRIVER ELEC. GOVERNOR
SOLENOID FUEL
ELEC. GOVERNOR ACTUATOR
SWITCH, HIGH COOLANT TEMP
767
765
769
766
768
0
N/C
14
FRONT
14
0
14
4449
IC
6
6
1
3
5
0
4
2
IM
DEG
0
765
766
14
766
765
767
770
771
768
767
769
1
2
3
4
5
6
7
8
9
10
11
12
LEGEND [CONT.]:
IC IGNITION COIL
IM IGNITION MODULE (ON DISTRIBUTOR)
LOS SWITCH LOW OIL PRESSURE
SC CONTACTOR, STARTER MOTOR
SM STARTER MOTOR
WLS SENSOR, COOLANT LEVEL
29
16
30
7
6
5
2
4
3
ENGINE
FOOT
12
13
17
9
35
18
16
8
40
39
36
30
16
43
44
TO
ENGINE
BLOCK
34
35
41
38
18
44
32
33
22
42
20
31
21
20
7
6
5
37
1
13
MOUNTING BASE
15
14
12
11
REAR BEARING
CARRIER
HARNESS
WIRE
TO
STARTER
CONTACTOR
TO
STARTER
BOLT
TO
ENGINE
18 BLOCK
14
16
10
4
3
2
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Mounting Base — Drawing No. 0E6266-F
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Mounting Base — Drawing No. 0E6266-F
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
21
22
23 *
24 *
25 *
26 *
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
PART NO.
0E5822
052860
052251
052257
052252
052259
052891
0536210213
074906
047411
055414
026850
022097
022473
049813
0A1694
052213
025507
027482
022129
045771
051756
046526
022131
055934M
077483
058665
038804D
038805AA
021991
049814
046526
022131
075763
050331
050331A
0A4010
052858
061902
059473
049820
QTY.
1
4
4
4
4
4
4
1
1
1
1
2
1
2
1
4
1
3
2
1
1
1
1
1
1
REF.
REF.
1
1
1
1
2
1
1
1
1
2
2
1
1
2
DESCRIPTION
BASEFRAME, WELDMENT 3.0L FORD
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY GRNDWIRE 11"/3/8 & 5/16 LUG
SCREW HHTT M6-1.0 X 20 BP
SCREW HHC M6-1.0 X 16 BP
LUG SLDLSS #2-#8 X 17/64 CU
WASHER SHAKEPROOF EXT 1/4 STL
WASHER LOCK M6-1/4
WASHER FLAT M6-1/4 ZINC
NUT HEX M6 -1.0 G8 YEL CHR
1-1/2" BUTTON PLUG
SCREW HHC M10-1.25 X 20 G8.8
WASHER SHAKEPROOF EXT 7/16 STL
WASHER SHAKEPROOF EXT 5/16 STL
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
CLAMP VINYL .75 X .343 Z
BATT 12VDC 75-AH 26
BATT 12VDC 90-AH 27F
CABLE BATT RED #4 X 20.00
CABLE BATT BLK #4 X 30"
EARTH STRAP
SCREW HHC M10-1.5 X 25 G8.8
WASHER LOCK M10
WASHER FLAT 3/8 ZINC
BOOT BATTERY CABLE
BATTERY POST COVER BACLK BATTERY POST COVER RED +
SCREW HHC M8-1.25 X 60 G8.8 FT
NUT TOP LOCK FL M8-1.25
HOLD DOWN BATTERY
HOLD DOWN BATTERY
NUT HEX LOCK M8-1.25 NY INS
* NOT SHOWN-USED TO HOLD DOWN I/N 32
31
32
3
30
31
LATCH DETAIL
38
32
4
34
18
17
43
27
2
40
4
37
35
25
RADIATOR
SUPPORT
49
4
33
4
STATES FOAM IS ON FAR SIDE
STATES FOAM IS ON NEAR SIDE
4477
49
25 4
4
4
13
11
9
SEE LATCH
DETAIL
26
4444
TO "A"
TYPICAL OF ROOF PANEL THAT
REQUIRE INSULATION.
SECURE AS SHOWN.
36
"B"
52
4
16
6
4
"A"
29
49
8
12
15
48
53
17
18
5
52
48
"B"
20
10
14
7
28
11
19
9
45
45
53
24
4
17
41
42
23
4
18
40
17
1
26
39
TO "B"
(2-PLCS)
18
10
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Enclosure — Drawing No. 0F1142-B
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Enclosure — Drawing No. 0F1142-B
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50 *
51
52
53
PART NO.
0E8411
0E8042
0E8041
0C2454
0E8402
0E7808
0E7809
0E8387
0E6986
0F5552
089961
0A2115
0E8404
0D2538A
0D2538
078115
022097
022473
0E7570
0E7571
070015
0E7662
0D2537A
0D2537
0D2023
0E7869
0E8001
0F5551
0E8406
0D3037A
0C7781
0E7794
0E8052
0D3037
0E8007
0E8008
0F1130
0E8055
026850
0912970063
0912970064
049813
0E8665
0E7829U
0E7829N
0E7829T
0E7829S
0E7829R
0E7829P
0E8441
0E7829A
0E7829B
043116
QTY.
1
1
1
62
1
1
1
1
2
1
2
4
1
1
1
8
12
12
2
4
4
4
1
1
3
2
1
1
1
1
2
1
1
1
1
1
1
1
4
2
2
2
1
2
2
1
1
2
4
1
1
2
8
DESCRIPTION
INTAKE DUCT HSB
DUCT DISCHARGE RH FRONT
DUCT DISCHARGE LH FRONT
SCREW TH-FRM M6-1 X 16 N WA Z/JS
BAFFLE REAR BOTTOM
POST CORNER LH REAR
POST CORNER RH REAR
BAFFLE REAR TOP
DOOR COMPARTMENT SIDE
SUPPORT R/H SIDE
FOAM STRIP 3/4" WIDE X 3/16" THK (40" LG)
WASHER NYLON .257
BRACKET STIFFENER RH FRONT
HINGE LIFT OFF TYPE B KNUCKLE
HINGE LIFT OFF TYPE B PIN
WASHER SELF LOCKING DOME
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
GAS SPRING
BALL STUD GAS SPRING MOUNT
NUT HEX 5/16-18 LOCK
SCREW WING M6-1.00 X 25
HINGE LIFT OFF TYPE A KNUCKLE
HINGE LIFT OFF TYPE A PIN
GASKET CLIP-ON SELF GRIPPING (84" LG)
BRACKET STIFFENING BACK
MUFFLER BOX
ROOF, W/SHOCK MOUNT
BRACE FRONT TOP
LATCH 1/4 TURN NONLOCKING
PAWL DOOR HSB
SUPPORT LH SIDE
MUFFLER BOX TOP
LATCH QUARTER TURN LOCKING
POST CORNER LH FRONT
POST CORNER RH FRONT
BRACE, FRONT BOT 3.0L FD STEEL
DUCT DISCHARGE MID FRONT
WASHER SHAKEPROOF EXT 1/4 STL
ASSY WIRE 14AWG 7.5 #0 GRN/YEL
ASSY WIRE 14AWG 7.5 #0 GRN/YEL
NUT HEX M6 X 1.0 G8 YEL CHR
BRACKET STIFFENER LH FRONT
AI BRACE PANEL
AI ROOF PANEL 2
AI SUPPORT RH PANEL
AI SUPPORT LH PANEL
AI CORNER POST PANEL 2
AI CORNER POST PANEL 1
KIT INSULATION 3.0L HSB
AI ROOF PANEL 1
AI DOOR PANEL
SCREW HHC M6-1.0 X 12 G8.8
* ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF 0E8441
33
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Control Panel — Drawing No. 0E7118-K
34
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Control Panel — Drawing No. 0E7118-K
ITEM
PART NO.
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
0E7195
0E7196
0E7197
0E7193
0E7194
0E4494
082573
032300
022676
067682B
060015
054199
0C2657
099076
040213
0E9668
067680
0E6875A
0E6881 *
0C5139 *
0C5142 *
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
REF.
REF.
REF.
22
23
24
0E3161
054450
0D5070A
1
1
1
25
26
27
0E2514
0A9457
0E7539
1
1
1
28
29
30
31
046357 *
0D3719B
057073
0E7283
0E3628
0E3664
0E7539A
0D4698 *
0E7252
0C1229
32
33
34
35
36
REF.
1
1
1
1
1
1
REF.
1
1
DESCRIPTION
CONTROL BOX HSB
COVER FRONT PANEL HSB
COVER TOP PANEL HSB
DECAL WARNINGS HSB
DECAL CONTROLS HSB
SWITCH ROC DPDT ON-OFF-ON
SWITCH ROCKER DPST 125V SPD
HOLDER FUSE
FUSE 15A X AGC15
FUSE 4A SLO BLO GLASS
FITTING CONDUIT 90D 3/8"
DECAL DANGER HIGH VOLTAGE
TRANSFRMR 16V 6VA
TRANSFORMER 16V 56VA
PCB SUPPORT SNAP-IN 1/4"
ASSY PCB HSB CONTROLLER
ASSY VOLTAGE REGULATOR 60HZ
RELAY 12VDC C FORM W/DIODE
SOCKET RELAY
CONN DEUTSCH RECEPT GY/FLN
CONN DEUTSCH RECEPT WDGE
BLKHD
ASSY BOSCH GOV DRIVER
CIRCT BRK 5.5 X 1 ETA 46-500-P
ASSY 2A 12V UL BATTERY
CHARGER
FITTING CONDUIT STR 1-1/2"
DECAL NEUTRAL
DECALCUSTOMER CNNCTN XFER
SW
BLOCK TERM 20A 6 X 6 X 1100V
DECAL CUSTOMER CNNCTN
JUNCTION BLOCK 3/8-16
CB 0150A2P240V S QN2 LL
CB 0200A2P240V S QN2 LL
BASE QN CIRCUIT BREAKER
DECAL TB1 HSB CONTROL PANEL
BLOCK TERM 20A 6 X 3 X 1100V
BRACKET CB 221.5 X 102
DECAL WARNING ELECTRICAL
SHOCK
ITEM
PART NO.
QTY.
37
38
39
0C1127
0A1441B
0E7128
1
1
1
40
41
42
0E7358
074908
0C5141
8
6
1
43
44
45
46
47
49
50
51
52
53
54
55
56
57
58
59
60
0C2699
0C2323
022155
0C2265
022264
020911
066849
022152
023897
051716
090388
042568
022097
022473
0441140187
070370
023762
11
4
15
4
4
2
2
4
3
2
2
4
8
6
2
2
1
61
62
63
64
65
66
67
68
69
055444
030468
049939
022158
022985
038750
0A2115
0C2454
0F6146
1
1
1
1
1
2
4
4
1
DESCRIPTION
DECAL AVR COVER
COVER PLATE, AVR
HARNESS CNTRL PNL (NOT
SHOWN)
SCREW PPPH HI-LO #4-24 X 3/8
SCREW HHTT M5-0.8 X 10 BP
CONN DEUTSCH GASKET 8/12 POS
DT
SCREW PHTT #6-32 X 3/8 ZYC
SCREW PHTT #6-32 X 5/8 ZYC
WASHER LOCK #6
SCREW PHTT M4-0.7 X 12 ZYC
WASHER LOCK #8-M4
SCREW PPHM M5-0.8 X 30 ZINC
SCREW HHTT M5-0.8 X 16
WASHER LOCK #10
WASHER FLAT #10 ZINC
NUT HEX M5-0.8 G8 YEL CHR
SCREW HHTT M6-1.0 X 12 ZINC
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
WIRE ASSY 3" X (2) 3/16" TABS
WASHER MICA .203
WASHER SHAKEPROOF EXT #10
STL
HEATSINK
WASHER STEP NYLON .20
RECTIFIER MSC 12A 600V 1N1206R
NUT HEX #10-32 STEEL
WASHER FLAT #6 ZINC
SCREW HHC M6-1.0 X 30 G8.8
WASHER NYLON .257
SCREW THF M6-1 X 16 N WA Z/JS
HANG TAG 2 WIRE START (NOT
SHOWN)
* ITEMS INCLUDED AS PART OF I/N 39
35
36
50
24
2
25
58
43
55
57
25
54
53
42
61
60
38
61
24
53
60
14
85
36
35
39
51
58
57
30
69
31
87
39
GROUND
WIRE
32
86
36
35
39
35
68
65
79
17
66
67
REMOVE
& REPLACE
1
49
78
46
21
20
46
84
43
42
49
42
16
63
38
64
88
18
47
47
4
15
47
43
2
19
80
81
26
42
38
42
81
6
48
7
36
43
3
5
42
44
36 35
89
28
27
40
33
34
82
41
47
45
83
74
34
31
72
32
12
36
35
38
10
29
42
BAFFLE
REAR UPPER
37
42
8
35
84
30
73
11
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Engine — Drawing No. 0F6836-B
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Engine — Drawing No. 0F6836-B
ITEM
PART NO.
QTY.
1
2
3
0E6201
0E8824
0E8963
1
2
1
4
5
6
7
8
0E9020
0A1232
0A7801B
0A5610
0E6308
1
1
1
1
1
9 **
0E7804
1
10
11
12
14
15
0D3488F
0E7996
0E8006
0A6751
0E0561
1
1
1
1
1
077043H
1
16
17
0E6729
0E6703
1
1
18
19
20
21
0E6667
0E5048
035579
0A8584
1
1
1
1
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
083896
084929
055597
0F6151
057823
056739
047411
022097
022473
047411
040976
022129
022145
045771
049814
049821
059980
0D5417
046526
022131
059982
098780
051769
6
6
1
1
1
1
6
6
6
4
8
28
22
1
6
16
4
REF.
18
11
4
2
3
DESCRIPTION
ENGINE 3.0L FORD (FD) (MAKE)
STAMPING ENG FOOT 3.0L FORD
PULLEY CRANKSHAFT 3.0L FORD
RD
BRACKET DC ALT 3.0L FORD
D.C. ALTERNATOR ASSY
PULLEY POLY-V 82 OD.
BRACKET ALTERNATOR
PULLEY WATERPUMP 3.0L FORD
(RD)
HARN IGNITION 3.0L FORD (NOT
SHOWN)
BELT SERPENTINE 38.35
CLUTCH COOLING FAN FORD
FAN 18" 7 BLADE STEEL ECS
SWITCH HI-TEMP 245D X 3/8NPT
ASSY WATER LEVEL SENSOR C/E
PL
CONDUIT FLEX .25"ID (6"LG) (NOT
SHOWN)
STARTER DELCO-REMY 12V
COVER FLYWHEEL ACCESS 3.0L
HSB
ENGINE ADAPTER 3L FORD
FLEXPLATE 3.0L FORD
BUSHING REDUCER 1/4 TO 1/8
SWITCH OIL PRESSURE 10PSI
2POL
WASHER LOCK 1/4-M6 SS
WASHER FLAT 1/4 SS
SCREW HHC M12-1.75 X 85 G8.8
CAP RUBBER
CLAMP HOSE #10 .56-1.06
RELAY SOLENOID 12VDC PNL MNT
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 16 G8.8
SCREW SHC M8-1.25 X 20 G12.9
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M10-1.5 X 25 G8.8
SCREW SHC M8-1.25 X 30 G12.9
SCREW HHC M10-1.5 X 25 G10.9
SCREW HHC M10-1.0 X 25 G10.9
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
SCREW SHC M12-1.75 X 45 G10.9
SCREW HHC M12-1.75 X 65 G8.8
WASHER LOCK M12
ITEM
PART NO.
QTY.
47
48
49
50
51
53
54
55
56
049808
051430
045773
0E6203C
0E6679
049226
091526
093278
0F7000
4
4
3
1
2
7
3
4
1
57
58
60
61
62
0E7163
0E5527
0E7202
085296
0E6203D
2
2
2
6
1
63
64
65
66
67
68
69
70 *
71 *
72
73
74
75
057772
057765
055596
069860C
057822
069811
061012
065852
0A2111
057073
066849
022152
0E7880
1
1
1
1
2
1
1
1
1
1
2
2
2
76
0E7880A
4
77
0E7880B
1
78
79
055934C
027482
1
1
80
81
82
83
84
85
86
87
88
89
0E8940
0A7387
022097
022473
055934H
0F5966
022985
036261
0F6658
0F6809
1
2
4
4
2
1
3
3
1
1
DESCRIPTION
WASHER FLAT M12
WASHER SHAKEPROOF INT 1/2
NUT HEX M12-1.75 G8 YEL CHR
COIL IGNITION 3.0L FORD
BRACKET IGN COIL 3.0L FORD
WASHER LOCK M5
SCREW PPHM M5-0.8 X 12 ZNC
SCREW HHTT M5-0.8 X 25 BP
HARN ENGINE 3.0L FORD HSB CAR
(NOT SHOWN)
GASKET EXHAUST 3.0L FORD
MANIFOLD EXHAUST 3.0L FORD
HEAT SHIELD 260 X 80 HOT
SCREW HHC 1/4-20 X 1/2 SS
WIRE SET 3.0L FORD (NOT
SHOWN)
WASHER NYLON .565
ADAPTER M14-1.50 X 3/8 NPT
BARBED STR 3/8NPT X 3/8
HOSE OIL DRAIN ASSY 21"
CLAMP HOSE #8 .53-1.00
CAP HEX 1/4 NPT BRASS
PLUG STD PIPE 1/8 SOCKET HEAD
SPRING CLIP HOLDER .37-.62
SCREW SWAGE 10-32 X 5/16 Z/YC
JUNCTION BLOCK 3/8-16
SCREW HHTT M5-0.8 X 16
WASHER LOCK #10
CLIP SPARK PLUG 3P
SCREWMOUNT (NOT SHOWN)
CLIP SPARK PLUG 2P
SCREWMOUNT (NOT SHOWN)
CLIP SPARK PLUG 3P FREEHANG
(NOT SHOWN)
CLAMP VINYL .5 X .406 Z
WASHER SHAKEPROOF EXT 5/16
STL
SPACER FLEXPLATE HSB
SCREW HHC M10-1.5 X 40 G10.9
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
CLAMP VINYL .62 X .406 Z
REFLECTIVE HEAT SHIELD 3.0L FD
WASHER FLAT #6 ZINC
RIVET POP .125 X .275 SS
COVER EGR
ADAPTER, WATER PUMP
* NOT SHOWN-USED TO HOLD OIL DRAIN ASSEMBLY.
** NOT SHOWN
37
38
FRAME
9
8
3
11
10
9
25
26
12
"A"
27
20
15
1
4
21
3
12
TO WATER
PUMP
22
24
24
23
6
2
17
12
7
12
15
28
5
32
13
31
18
12
14
33
TO "A"
29
35
30
12
TO
THERMOSTAT
HOUSING
TO
ENGINE
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Radiator — Drawing No. 0F6848-B
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Radiator — Drawing No. 0F6848-B
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
20
21
22
23
24
25
26
27
28
29
30
31
32
33
35
PART NO.
0E9947
0E6340
0E8531
0E6398
0F6630
080713
076749
049814
022131
046526
045772
035685
0E8562
058443
0C2454
048031C
029032
046627
069811
065852
0A2111
052250
035461
0C7649
069860C
0F6746
0F6631
0F6657
055934N
092079
022097
047411
QTY.
1
1
2
1
1
1
1
4
8
4
4
6
1
4
9
1
1
1
1
1
1
2
1
1
1
1
1
2
2
2
2
2
DESCRIPTION
RADIATOR R-IN,L-OUT 658X489X49
VENTURI 3.0L FORD HSB
SIDE SUPPORT RADIATOR HSB
TUBE LOWER RAD 3.0L FORD HSB
HOSE RADIATOR UPPER
BRACKET COOLANT TANK
TANK COOLANT RECOVERY
SCREW HHC M10-1.5 X 25 G8.8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
NUT HEX M10-1.5 G8 YEL CHR
CLAMP HOSE #28 1.32-2.25
FAN GUARD HSB
SCREW CRIMPTITE 1/4-20 X 5/8
SCREW TH-FRM M6-1 X 16 N WA Z/JS
CLAMP HOSE BAND 1/4
HOSE 9/32 ID (30" LG)
CAP RADIATOR
CAP HEX 1/4 NPT BRASS
SPRING CLIP HOLDER .37-.62
SCREW SWAGE 10-32 X 5/16 Z/YC
TAPE FOAM 1 X 1 (27" LG)
BARBED STR 1/4 NPT X 3/8
CLAMP HOSE .38-.87
HOSE OIL DRAIN ASSY 21"
TUBE UPPER COOLANT C4 3.0L
HOSE RADIATOR ENGINE
SUPPORT TUBE RADIATOR
CLAMP VINYL 1.31 X .281 Z
SCREW HHTT M6-1.0 X 25 BP
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 16 G8.8
39
Section 9 - Exploded Views and Parts
42
43
41
15
"B"
28
21
8
40
5
16
2
4
10
29
32
30
29
11
17
6
1
7
9
13
31
29
12
6
3
34
33
14
TO
AIR
CLEANER
13
TO "B"
18
26
27
19
28
26
25
20
40
39
Liquid-cooled 30 kW Generators
Fuel System — Drawing No. 0F6849-A
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Fuel System — Drawing No. 0F6849-A
ITEM
PART NO.
1*
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
25
26
27
28
29
30
31
32
33
34
35 **
36 **
37 **
38 **
39
40
41
42
43
--------075580
0E7691
039253
022145
022129
045771
042907
0C2454
026307
0E1056
0E6584
057823
059194
044117
0D1509
050279
0E6123
0E6586
0E4395
057753B
047487
022097
051751
035685
0C7649
047290
047290
0A4121
0E6609
049099
055934M
047411
022097
O22473
0E9295A
0E6382A
0E7121
0E6376A
0F2119
QTY.
1
1
1
2
2
4
2
2
2
1
1
1
2
1
1
1
1
1
1
1
1
4
8
4
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DESCRIPTION
WELDMENT MOUNTING BASE
FLANGE FUEL INLET
ASSY REGULATOR 3.0L NG OR LPV
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M8-1.25 X 16 G8.8
SCREW TH-FRM M6-1 X 16 N WA Z/JS
ELBOW 90D STREET 3/4
FUEL HOSE ASSY NAT.GAS/L.P.V.
BRACKET REGULATOR 3.0L FORD HSB
CLAMP HOSE #10 .56 - 1.06
HOSE 5/8 ID LPG & NG (20" LG)
BARBED STR 3/8 NPT X 5/8
DECAL INLET PRESSURE
DECAL FUEL INLET NG
INTAKE ADAPTER 3.0L FORD-BOSCH
GASKET BOSCH 32
ACTUATOR BOSCH 32 GOVERNOR
HOSE 1.5 ID X 2 LG 20R4
SCREW SHC M6-1.0 X 18 G12.9
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 50 G8.8
CLAMP HOSE #28 1.32-2.25
CLAMP HOSE .38-.87
HOSE 3/8 ID SINGLE BRAID (305mm [22"] LONG)
HOSE 3/8 ID SINGLE BRAID (432mm [13"] LONG)
VALVE PCV
GROMMET ROCKER COVER 3.0LFORD
BARBED EL 90 3/8 X 3/8 PLST
CLAMP VINYL .75 X .343 Z
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
ASSY THROTTLE 27MM
VENTURI HOLDER W/32MM ACTUATOR
O-RING 47.625 ID X 2.38 WIDTH
VENTURI, 27 ID THROTTLE W/CHOK
O-RING 45.63 ID X 2.62 WIDTH
* SHOWN IN OTHER VIEW
** NOT SHOWN-USED TO HOLD #31 IN PLACE
41
Section 9 - Exploded Views and Parts
12
8
7
5
18
42
LOCKTIGHT
15
7
17
1
4
16
31
30
LEADS
2
6
9
21
13
LOCKTIGHT
3
10
11
20
19
14
Liquid-cooled 30 kW Generators
Alternator — Drawing No. 0F5092-B
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Alternator — Drawing No. 0F5092-B
ITEM
PART NO.
QTY.
1
0F1659A
0F1657A
0F1655A
0F5073A
0E7413A
0F1660A
0F1658A
0F1656A
0F5074A
0E7412A
0E5706
0E5048
0E5048B
0E5048A
0E6668
0E6076
046526
051755
04576100BK
04576100BF
043123
051779
0E7587
023365
092980
057192
0A2602
042558
0A2601
022264
038150
077043F
077043F
1
1
1
1
1
1
1
1
1
1
1
REF
REF
REF
1
1
8
4
4
4
4
4
1
1
4
4
1
1
1
4
4
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
ROTOR REPLACEMENT PARTS
30
047248
31
070892
1
1
DESCRIPTION
ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390__30AD1 HSB TECUM
RTR 390 40KW 1P DIRECT HSB
STR 390 15AD HSB (382MM LONG) (2.5L FORD)
STR 390 20AD HSB (382MM LONG) (2.5L FORD)
STR 390 25AD HSB (382MM LONG) (2.5L FORD)
STR-390__30AD1 HSB TECUM
STR-390--40AD HSB (433MM LONG)
REAR BEARING CARRIER 390/DRCT
FLEXPLATE 3.0L FORD
FLEXPLATE 2.5L FORD
FLEXPLATE HSB 3.9L CHRYSLER
FLYWHEEL ASSY 3.0L HSB LG GEAR
REVCOR FAN 10.75 X 2 W/PRESS DIS
WASHER LOCK M10
SCREW HHC M10-1.5 X 16 G8.8
STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD)
STUD M14-2.0 X 540 G5 ZINC
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
ASSY BRUSH HOLDER 390/HSB
WASHER SHAKEPROOF INT #8
SCREW PPHM M4-0.7 X 25
SCREW SHC M10-1.5 X 30 G12.9
WASHER FLAT .688 ID X 3.25 OD
KEY SQ 3/8 X 1 STEEL
SCREW HHC M16-2.0 X 45 G8.8
WASHER LOCK #8-M4
WASHER FLAT #8 ZINC
CONDUIT FLEX 1-1/4" (30" LG - 3.0L FORD & 3.9L CHRYSLER)
CONDUIT FLEX 1-1/4" (18" LG - 2.5L FORD)
BALL BEARING-45 MM
SLIP RING -MACHINED-
43
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Exhaust — Drawing No. 0F0968-B
21
13
2
11
18
1
19
17
16
7
8
16
16
17
6
18
TO
MANIFOLD
19
8
TO
COMPARTMENT
10
15
20
16
17
3
10
20
17
5
9
TO
MANIFOLD
12
13
14
3
4
12
ITEM
PART NO.
QTY.
1
2
3
4
5
6
7
0F0738
0F6258
044149
0F1008
0F1009
039288
0E5914
1
1
2
1
1
1
1
8
9
10
11
0E8726
0E0170
036797
080762
2
2
2
1
44
DESCRIPTION
MUFFLER 7"X9"-(2)2"IN/2.5"OUT
PIPE MUFFLER OUT
GASKET EXHAUST RING
EXHAUST PIPE LH 3.0L HSB
EXHAUST PIPE RH 3.0L HSB
SCREW HHC M8-1.25 X 55 G8.8
BRACKET MUFFLER 3.0L FORD
HSB
STRAP MUFFLER
EXHAUST BLANKET 750MM
BOLT U 5/16-18 X 2.25
BOLT U 3/8-16 X 2.62
9
ITEM
PART NO.
QTY.
12
13
14
15
16
17
18
19
0E8816
085917
0D2611
039253
022145
022129
045771
0C2454
2
8
4
2
4
7
3
4
20
21
022259
022241
4
2
DESCRIPTION
EXHAUST FLANGE 2" PIPE
WASHER LOCK 3/8 SS
SCREW HHC 3/8-16 X 1-3/4 SS
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW TH-FRM M6-1 X 16 N WA
Z/JS
NUT HEX 5/16-18 STEEL
NUT HEX 3/8-16 STEEL
Section 9 - Exploded Views and Parts
Liquid-cooled 30 kW Generators
Air Cleaner — Drawing No. 0F6850-A
1
2
3
4
5
6
7
8
9
ITEM
1
2
3
4
5
6
7
8
9
PART NO.
0E5193
0E0519A
049226
049815
0C8127
022127
062974
0A5547
037561
QTY.
1
1
4
4
1
1
1
1
1
DESCRIPTION
PLATE AIR CLEANER ADAPTER
ADAPTER CARBURETOR W/PVC CONN
WASHER LOCK M5
SCREW HHC M5-0.8 X 16 G8.8
ELEMENT AIR CLEANER
NUT HEX 1/4-20 STEEL
STUD TH 1/4-20 X 4-1/2 G2 ZNC
COVER - AIR CLEANER
NUT WING 1/4-20 NYLK
45
Section 10 – Warranty
Liquid-cooled 30 kW Generators
GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN®
"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will
be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace
any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to
be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian Authorized
Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by
the purchaser/owner. This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators sold and
rated for use in "Standby" applications.
WARRANTY SCHEDULE
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
Engine - All Components
Alternator - All Components
Transfer System - All Components
Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the
responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be
repaired promptly by the owner.
All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate
Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Guardian generators that utilize non-Guardian/Generac replacement parts.
• Guardian generators utilizing non-Guardian/Generac automatic transfer switches.
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by
Generac Power Systems.
• Any Guardian generators used as rental or trailer mounted applications.
• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility
power service does not normally exist.
• Costs of normal maintenance, adjustments, installation and start-up.
• Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where
integrity of paint applied is compromised.
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all
mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not
cover repair when normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty
period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES
NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
GENERAC® POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part No. 0F6866
Revision 0 (07/26/05)
Revision (02/01/05)
Printed in U.S.A.